Thomas robinson



May 29,1928.` T- ROB-NSW RDOFING ELEMENT origina; Filed April 1o, 1925'.

vIN NTR .5 B l n l a l P ,M/w (M A v ATToRNEYs 'Reiued May v29, 192s.

(UNITED :STA

ras PATENT orifice.'

THOMAS MBINSON, F NEW'YORX, N.l Y.

` L ln'oor'mo ELEMENT.

' Original lo. 1,585,692,

reissue led September 1,

l0 whic is produced of ingredients which are a available at low prices, and -may be utilized in the manufacture of the new product with little labor.

Prepared rooings of various kinds are l5 nowin wide use, and they afford numerous advantages over wooden shingles, slate, tiles and the like. Such roofings are cheaper than the older materials, may be handledandlaid more conveniently,` and, as lco pared with 4wooden shingles, they reduce the fire hazard to a considerable extent. These prepared roducts are soldcommercially in various orms, such as in rolls',fand vas single and multiple-unit shingles, and in the/types 2 which have met with the greatest commercial success, they include a base made of an Vimpregnated rooting felt, or of asbestos board, or of wood fibre products. To the surface of the base, prepared by well-known n methods, it is usual, in nearly all forms,.to` apply a coating of some weather resistant i product, over which isplaced a coating of a good-wearing material, such as crushed slate. A. typical example "l5 roofing consists ofa felt made of wool and rags, suitably compacted, and saturated with asphalt. Over one or both surfaces of this -felt base is appliedI a layer. of asphalt of a melting point such ythat .it will withstand 4, solar heat, and then over the upper surface is applied a coating of/crushed slate, which is partially embeddedl in the coating layer beforethe latter has completely hardened.-

Such products are satisfactory `.in many l respects, although a roofingl built up of a' felt base'v deteriorates Imore or less rapidly upon exposure to the Weather due to the rottin of the felt. This is particularly'v unde-A sirable. when the roofing elements are the 0 formof shingles and laid in courses, `since -'the exposed edges warp or curl and the roof takes on an unsightly appearance. Another` objection lies in the fact that these products are nearly always made of a uniform thickness from one end durable,

of such a preparedare of varying sizes,. then the lar tothe other and when:

dma nay 25, 192e, serial No. 22,057, mea apra 1o, 192:5. alienation mr 1927. serial No. 216,970.

laid in courses, the individual elementsfdo not lie close together throughout their length but cavities occur at the ends of the elements. Also these units are commonly made with a comparatively thin base, which is lacking in rigidity. Another major objection is that the base products, such as felt, asbestos board, etc., are quite expensive, even though cheaper than wood.

The object of the present-invention is to provide a new roofing product which may be manufactured at a lower cost than the preparedroofings now in use and in any of the shapes and .forms desirable for building purposes. More specifically, I intend to provide arproduct which, by reason of the manner in which it is made, may have vary-' ingdegrees offlexibility and which possesses the strength and durability desired for products of this character. The new product is composed throughout of materials which do not .deteriorate upon exposure, and may readily be made in the tapered form,l which is most suitable for roofing pur oses.

Vhile the new product may "i, made of various materials and in difiere-.t ways, I

prefer to construct it of a body of commif nutedmaterial bound together 2y a plastic binder and a jacket of flexible iibroussheet material encasing the body. Oneconvenient method of'manuacture involves the use oi al jacket sheet which is folded upon itself and receives the bodyfwithin the fold. In making a tapered element the decrease in thickness toward the rear end would ordinarily decreasethe rigidity of the element, but the new ,element may be made of uniform ris gidity throughout its len h, although the thickness is variable, by tie use of commi nuted inert materials graded for size, or of different speciiic gravities. The heavier ma# terial is used in that part of the filler which is in lthe thinner part of the element, when materials of different specific gravities are used throughout the filler but the particlesv er lparticles are arranged so as to lie in the t 'nner part of the filler, While the smaller particles lie in that part of the filler which occupies the thicker or butt end of the element. The dev sired result is brought about bya proper grading -or proportioning of the ingredients in the iiller, and a uniform rigidity throughout the element can readily be the same materialv is obtained in m the manner presently` to be described, even though the -thickness of the element may vary within-wide limits from one end to the other.

For a better understanding of the invention, reference will now be made to the accompanyinv drawings, in which, y

Figs. l and 2 are face views of multiple unit and single unit shingles, respectively,v

Fig. 3 is a face view of a modified form of single unit element,

Fig. 4 is' a longitudinal sectional view of one form of the new product,

Fig. 5 is a sectional view on an enlarged scale of a ortion of the element shown in Fig. 4, an taken on the linea-5 of that figure,

Fig. 6 is a sectional view showing a portion of the end of the novel product at one stage in the maufacture,

Fig. 7 is a longitudinal sectional view of a modified form of element,

Fig. 8 is a longitudinal sectional view of another modification, and

Fig. 9' is a face view ofa completed three unit shingle.

Referring now to these drawings, there is shown in Fig. 1, a three unit strip-shingle 11 provided with cut-outindentations 12, in its forward edge.v Similar cut-outs 13 of half Width are formed at its side edges andy when a series of these units is laid in a course, the cut-outs give the intervening areas 14` the appearance of spaced single shingles, and the rear ends of the cut-outs vbeing concealed in the completed roof by the butts of the shingles in the overlapping course. l f

In Figs, 2 and 3. are shown single elements, the form shown in Fig. 2'being made With cut-outs 15 along its side edges, While the unit shown in Flg. 3 is ,intended to be laid with its edges 16 spaced from those of the next adjacent unit during the laying operation.

The new product may be made in any of the forms shown and is preferably given a tapered cross-section from front to rear. One form of the product illustrated in Figs. 4 and 5'1nay consist of a jacket sheet 17 which is substantially twiceas long as the lengthof the unit and folded transverse- :1y upon itself, as at 18. This sheet may be made Aof.various materials, of which an asphalt-impregnated paper .is typical. It is preferably, though not necessarily, water-resistant and should have a fair degree ofv strength. `Itmay serve to confine the Inaterial -of which the new product is principally made, during the. course of in anufac.-

ture, Vand also contributesa certain amount.

ofstrength and durability to theiinal product. It is not depended on, however,` for its water-proofing qualities, nor for its rigidlty, and accordingly, various materials other than asphalt paper Will suggest themselves to those skilled in the art as being useful for the purpose, although asphalt paper is desirable because it is, among other things, of a low cost. For example, asbestos paper or a coarse grade of paper not impregnated, may be use In the production of thc element illustrated in Figs. 4 and 5, which includes a jacket sheet folded upon itself, the first step in the process of manufacture may be that of preparing the sheet of proper dimensions and folding it transversely, after which the sheet may be supported in any appropriate Way, preferably with the halves of the sheet at either side of the fold relieved from strain and spaced apart according to the thickness of the element to be produced. When a tapered element is to be made, the sides of the sheet are supported in diverging relation. Into the fold of the sheet there is now introduced thel filler, which is made up of a comminuted inert material, together with a plastic binding compound.Y This `inert material may be of various kinds, as, for example, crushed slate, crushed petroleum coke, infusorial earth, sand, gravel, pumice stone, with Which may be mixed ground cork of fibrous products such as asbestos, peat, and the like. The natural product known as asphalt sand may also y be used. The plastic binding compound is preferably a bituminous substance, such asl asphalt.

In the utilization of these materials in 10o the production of roofing elements, I find that a tapered element which is of superior quality, due to its substantially uniform rigidity,` may be made by employing a mixture of such inert materials forthe 105 filler, this mixture being made up of mate# rials vWhich are graded as to size, so that the density of the filler may be controlled, or of `two or more 'materials which have different. specific gravities.. I have found 110 that when the filler. or body of the element is made of crushed slate, the particles of which vary from a. fine dust to l, in size, for example, with asphalt as the plastic compound, this element has a substantially 115 uniform rigidity throughout when the fill! yobtained* by employin comminuate'dv Vmaterials i-n `thefiller whic Ahave different spe-.-

'cie gravities, producing these elements ua- 13o der such conditions that the heavier materials occup the thinner parts of the elei'nent. Unt er some conditions I contemplate that more than two materials of differpoint it has,

ent specific gravit'ies may be the purpose, the proportions the type of element to sions etc., `but in this second case the result'is the same as before. parts of the element the filler contains heavier particles of inert material, while on accountof the greater quantity of filler present in the butt end of the element, the use of lighter comminuted materials in thel filler does not reduce the rigidity to any considerable extent, and, in fact, a substantially uniform rigidity may be secured from one en of the element to the other by a Iproper selection of these materials, and by properly employed for depending on proportioning the quantlties which are employed.

In carrying out the process, the inert material is first mixture of two materials cific gravities is employed, properly proportioned so that the rigid of the final product may be that desired; After ,the grading operation is completed, the inert-materials used in the body are preferably mixed with the plastic compound an continuously agitated. The plastic compound is kept iuent by heat, andy when a quantity of the filler is introduced into the fold of the 'acket, the desired proportion of coarse and ne particles/or particles, isincluded. When slate and asphalt are employed, I have foundit desirable to heat the slate to a temperature substantially 'that at, which asphalt melts, and I have also found that since the melting point of the asphalt employed will, to some extent, determine product, because the sti er the asphalt becomes on hardening, the higher the melting the asphalt will also be selected in accordance with the type ,ofv product which is to be produced. The asphalt should,'of course, be selected in -any event so as to withstand solar heat without softening. When such a plastic matrix is introduce into the fold of the jacket, the heavier articles tend to sink into the depth of the old, while the lighter particles, some of which may be almost a dust, will remain suspended. This condition continues until the asphalt sets, and the desired disposition of the particles of different sizes isthus brought about. When materials of different specific gravities are employed, substantiallyA the same filling method is made use of.. The matrix consists of a quantity of a plastic composiof different spethe quantities are tion, Vtogether with comnnnuted inert Ina-- terials of different specific gravities, and in the desired roportions, which willdepend on the rigi ity which the final product'is be made, its dimen` In the thinner i graded as to size or when alight and heavy the ri idity of the final The stiffer the product to. be made, the larger the proportion of the heavier inert material. Vhen'this filler is introduced into the fold, the heavier inert material sinks into the bottom of the fold, thus occupying the position which it is intended to take, remain more or cupy the butt end of the element. sible to introduce materials of'different specific gravities into the fold in separate layers, if desred,ppouring the plastic compound over them after they are in position. In some instances this method is preferable.

In the event that the comminuted material which is employed with the plastic substance to form the body, is lighter than the plastic substance, for instance, if the body is made of a mixture of asphalt and infusorial earth or asbestos, then, owing to the diiferencein specific gravity between the comminuted material and the asphalt, the comminuted material will, to a considerable extent, remain in suspension while the element 1s being formed. Consequently,

in the bottom of the fold of the sheet the body will consist alto have.

less in suspension and ocmost entirely of asphalt, while the comwill lie in that `part of the minuted material body remote from the fold. the density of the bod will vary line of folding outwar ly,-and, as before the denser portions will lie nearer the fold. However, in

In this case this case-the desired rigidity is secured because the thinner parts of the body are occupied by heavier material, namely, the asphalt, and the parts of the body where the comminuted material appears, and which are therefore of less density, have an increased thickness.

After the body has been formed encased within the jacket and the plastic-material has become fairly hard, the element is subjected to finishing operations and if cut-outs are to be formed, these are made'by suitable cutting devices. l Since lthe cuttingoperationl is carried on before the filler has completely set, the butt 'end may lbeeasily molded to give the element a splay edge as indicated at'ZO. Preferably the tapering ofthe butt is continuous throughout the cut-out indentations. If desired, the butt end of the elethe edges y the ment may be finished by causing of the sheet to overlap so position illustrated in Fig. 7. For this purpose the jacket. used is .somewhat longer than the 4body so that parts 21 'and 22 of the jacket as illustrated' in Fig. 6, lie beyond the endof the body. After the filler has been placed in position, and preferably While it is still plastic, thesev extendin edges are turned inwardly, one upon the ot er, so that at the butt end the filler is enclosed in as to occup a double thickness of the sheet.

After the cut-outs have been formed, or immediately after the filler has set suiwhile the lighter /materials' from the -v It is posino luft

lll)

4 v f lapse ciently, if the element is to be Without cutments of varying characteristics, except in outs, the element is coated throughout with the selection of the proportions of different aithin layer 23 of a water-resistant comkinds of inert materials which are used. pound, preferably ofa plastic character It will be seen that the roofing product 5 which will harden on cooling. `Various bimay be made at extremely low cost since m tuminous products such as asphalt are suitall the materials employed in its construcable for the purpose. This coating layer tion are available at low prices, and no conseals the filler and makes the element watersderable amount of labor is employed. proof, as well as helps to protect the rein- One of the principal items of expense ofthe forcing sheet from wear. Over the sealing prepared roofings now sold, and which in- 75 coat, may be applied a thin layer 24 of clude a felt base, is the felt, which is coincrushed slate, crushed glass, etc.,-which proparatively expensive. Also, it is this part vides awear surface and enhances the apof the element which deteriorates most pear-ance ofthe finished product. rapidly when iny use. In the manufacture l5 In the element illustrated in Fig. 4, the of a unit with a felt base, it is difiicult to prosu comminuted filling material is shown as beduce a` shingle of tapered conguration, and ing of substantially the same size throughalso felt roofing shingles have a very conout the body of filler, and in this element the siderable degree of flexibility, which, to ends of the jacket at the butt end of the someextent, reduces their popularity. The

shingle are overlapped land the layer of present product, however, may be manufac- 85 crushed slate or the like, extends over the tured in any shape and form, and may be entire upper surface of the element and .given a tapered cross-section without addiaround the butt end. The element shown in tional4 cost or diiiiculty. -It may vary within Fig. 7 is a tapered element, in which com- 'wide limits as to rigidity, and is suitable v25 minuted materials of two different specific for all building purposes. Ihave found that 90v gravities are employed. In this element, in it may be readily nailed in place, and ma which the filler may be considered to conbe sawn with ease, and although it will orsist of a mixture of crushed slate and ground dinarily be made in elements which are com- Y cork, the slate is shown at 25 as occupying parativelystifl", -still it is not brittle and if the thin end ofthe element, while the larger subjected to blows the filler will not crack 95 particles of cork arerepresented as at 26 or break. in the butt end of thev element. In Fig. 8 I claim: y there is shown an unfinished element in l. A roofing element comprising the comwhich a single kind of comminuted material bination-'of a sheet doubled upon itself to 3.5 is employed, but having particles of difier- .provide a fold. and a body composed of a 100 ent sizes. In this element the inert mateardened plastic substanceand comminuted rial may be crushed slate, for example, and materials graded so that the density of the the heavier particles occupy the thin end of ody varies in different parts thereof, the the shingle, as indicated a 25', while the rigidity being substantially uniform.

lighter particles which remain substantially 2. Aroong element comprising the com- 105 suspended in the filler, occupy the space inbination of a sheet 'doubled upon itself to dcated at 26. It will be understood that provide a fold, and a body composed of a. the line of demarkation between the spaces ituminous matrix and an aggregate graded occupied by the different kinds of material as to weight and so disposed that the heavier or the different 'sizes of the same material, particles lie at the fold and the particles 110 is not as distinct as shown inthe drawin s, gradually decrease in weight from the fold where two quite distinct regions are in ito the opposite end of the element. cated merely for purposes of greater clarity 3. roofing element comprising the comin illustration. bination of a sheetdoubled upon itself to It will be seen that this new product may provide a fold with the plies of the sheet 115 be made'of any desired thickness, and that 'divergingfrom the line of folding, and a vno difficulty is involved in producingtal body composed of'a bituminous matrix and pered products. In its completed form all comminutedkmateial lying in the fold, this `the edges where the filler is exposed, are body being so formed that its density varies protected by.. a sealing coating, which not in different .parts'thereo with the-denser 120 only covers t-he side and vend edges of the portions lying nearer the fold, and the edges filler, but also theV edges of the cut-out in' of the sheet remote from the fold being dentations, so that there is no possibility of turned inwardly to loverlie the end of the water entering between filler and the jacket, body. V v

Ace so as to cause a separation. Elements of 4. A roofing element comprising the com- .varying de rees of rigidity or flexibility bination of a sheet doubled upon itself to may be pro uced bythe proper selection of rovide a fold and a body composed of a grades or kinds of comminuted material emliiardened plastic substance and` comminuted lployed, and the process of manufacturing material l ing within the fold, this body tdlifer in producing elebeing SO' Ormed, that its density Varies, i!) 130 tions lying nearer Vface of the sheet and the exposed edges of the body, and a layer ofy crushed mineral material embedded in the asphalt on one face of the sheet.

6. A rooting element comprising in combination a sheet doubled upon itself to provide a fold with the plies of the sheet diverging from the line of folding, and a body lying within the sheet and comprisin a u antity of particles of crushed slate of iferent sizes. the larger particles `occupying that art of the body lying nearest the linel of fo ding, and the size of the particles decreasing toward the opposite end ofI the shingle.

7. A tapered shingle comprising' in combination, a sheet of asphalt paper doubled upon itself to provide a fold, with the plies of the sheet diverging from the line of folding, a body lying within the sheet and comprising particles of crushed slate of differupon itself to provide a fold, with the ent sizes, the larger particles occupying that part of the body lying nearest the line` of folding, and a sea ing coat of asphalt capable of withstanding solar heat, applied to the outer faces of the sheet and the exposed edges of the body.v

' 8; A tapered bination, a sheet of asphalt paper doubled of the sheet diverging. from the line of olding, a body lying within the sheet and comprising a bituminous matrix and a mineral aggregate, the body being so formed that its density varies in different parts thereof with the denser portion lying nearer the fold, a plurality of cut-out indentations being formed in one edge of' the sheet and body, and a sealing coat of asphalt applied to the outer faces of the sheet `and t e exposed edges of the body, including the sides of the indentations. 'l

9. A tapered shingle comprising the combination of a sheet of fibrous material im- `preI nated with a'waterproofing compound d ou led upon itself to provide a fold, a body of crushed slate and an asphalticbinder lying within the fold, this gradually increasing thickness from the fold and the plies of the sheet on either side of the fold covering the opposite faces of the body and extending beyond 'the latter, the extending' portions being folded over the shingle comprising in comlies ody being of vend\ of the body in overlapping relation whereby the body is encased'withinithe sheet, and a sealing coat of asphalt covering the outer faces of the sheet and the portions of the body exposed at either edge of the latter.

l0. A roofing element comprising the combination of a body composed of a mass of solid material anda hardened plastic substance permeating said mass, this body being so formed that its density varies in different parts thereof, the rigidity being substantially uniform, and fibrous sheet material covering opposite faces of the body and securely affixed thereto.

11. A roofing element comprising the combination of a body composed of a mass of solid material and a hardened plastic `material permeating the said mass, this body tapering in thickness from one edge to the other and the body being so formed that its density varies in different parts thereof, with the denser vportions lying near the thin edge of the body, and fibrous sheet material covering opposite faces of the body and securely affixed thereto.

12; A roofing element comprising in combination a body comprising a quantity of particles of solid material of different sizes, this body tapering in thickness from one edge to the other, cles occupying that part rof the body lying near the thin edge and the size of the particles decreasing .toward the opposite edge ofthe element, and sheet material covering vopposite faces of the body and securely af fixed thereto.

13. A roofing element tapering in thickness from one end to ing in combination a body made up of solid material and a'hardened plastic substance, the` body being so formed that its density varies in different parts thereof, with the denser portions lying near the thin end of the body, sheet material covering opposite faces of the body and securely affixed thereto, and a sealing coat of asphalt applied to the outer faces of the sheet .material and the exposed edges of the body.

. 14. A roofing element tapering in thickness from one end to the other comprising 'in combination a body made up of a mass of Vsolid material and a hardened plastic substance prmeating the said mass, this body being so formed that its density varies in different parts thereof, with the rigidity substantially uniform, sheet material covering opposite faces of the body and securely affixed thereto, a plurality of cut-out indentations being formed in one edgel of the body and sheet material, Vand a sealing coat of asphalt applied'to the outer lfaces of the sheet and the exposed edges of the body, including the sides of the said indentations.

15. A roofing element tapering inthickness from one end to the other and compriswith the larger partithe other and compris'- phalt and eomminuted material, the body being so formed that its density variesnin different parts thereof, with the denser portions lying near the thin'end of the body, fibrous sheet material defining opposite faces of the body, a sealing coat of asphaliiic material applied to` the outer faces of the sheet material, and the exposed edges of the body, and a layer of crushed mineral Imaterial embedded in the asphalt on one face of the sheet and at the thick end of the element.

In testimony whereof I ax my signature.

THOMAS ROBINSON. 

